MICRO-LINE

™

For Milling Applications

REFERENCE MANUAL

lllllllllllllllll ACU-RITE INCORPORATED One Precision Way • Jamestown,NY 14701

Readout Systems Precision Glass Scales

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TABLE OF CONTENTS General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Packing List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warranty Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installing the Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installing the Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Display Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Setup Parameter Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Display Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Linear Error Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . 7 How to Determine the Linear Error Compensation . . . . . . . . . 8 Scale Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Count Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Testing the Scales. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Counting Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Repeatability Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operation Setting the Datum (Absolute Zero) . . . . . . . . . . . . . . . . . . . . . . . . 12 At Current Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Using an Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Incremental Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Centerline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Setting Datum on a Centerline . . . . . . . . . . . . . . . . . . . . . . . . 19 Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Locating Centerline Using Incremental Dimensions . . . . . . . . 21 2004-710 Ed B

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TABLE OF CONTENTS Bolthole Patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Creating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23 Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25

Troubleshooting Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Error Messages (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Keypad Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Reference Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 36 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 DRO Mode (2- and 3-axes systems) . . . . . . . . . . . . . . . . . . . . 37 Count Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Recalling the Last Datum Setting for International Units . . . . 38 Absolute and Incremental Dimensions . . . . . . . . . . . . . . . . . . 39

Scale Installation General Installation Instructions for the Scale . . . . . . . . . . . . . . . . 40 Installation Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Mounting Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Mounting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Scale Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Mounting Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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GENERAL Overview This manual will guide you through the installation, setup, and operation of the MICRO-LINE system. Use it to get your system up and running “out of the box” and as a quick reference guide for your day-to-day operations. Install the scales first, according to the instructions included in this manual. After the scales are in place, install the readout and then finish setting up the system. Here’s how a typical machine will look after the installation is complete:

Mounting Arm

MICRO-LINE

Readout

Z-axis Scale (if applicable)

X-axis Scale (behind the table)

Y-axis Scale

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GENERAL Preparation Packing List Verify that you have received all of the components for your system: • • • •

Readout instructions Installation instructions Mounting arm MICRO-LINE scale(s) - Cable mounting hardware - Scale mounting hardware • Warranty card If a component is missing, contact your MICRO-LINE distributor immediately for replacement. Warranty Records Complete the warranty card included with your MICRO-LINE system. The readout’s catalog and serial numbers are on the back of the display; the scale’s catalog number is on the scale assembly label; and the serial number is on the scale case. Copy the information here for your own records and mail the warranty card as soon as possible. Distributor: _____________________________________________ Address:

_____________________________________________

Telephone: _____________________________________________

Readout Axis #1: Axis #2: Axis #3:

Catalog No. ________________ ________________ ________________ ________________

Serial No. ___________________ ___________________ ___________________ ___________________

Date of Purchase: ____________________________________

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GENERAL Installing the Scales Install the scales according to installation instructions found in this manual. These general installation instructions are found on page 40. Please read the instructions completely before beginning. If specific bracket kit instructions are included, they supersede instructions contained within this manual.

Installing the Readout Follow the readout installation instructions that are included with your mounting arm bracket kit. The electrical specifications for the readout are listed on pg. 33. After the installation is complete, proceed to “Power Up.”

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GENERAL Power Up Press the switch on the back of the readout to power up the system. A series of tests will check that the display, keypad, and memory are all working properly. If a problem is detected, an error code will appear on the screen. (Error messages and solutions are listed on pgs. 31 - 32.) It is important to note that the E1 message will appear every time you power up your system and does not indicate a problem. It merely indicates that the system had lost power. To acknowledge the message, press the CLEAR key and proceed to the DRO mode. Note: If the E1 message appears at any other time during normal operation, refer to pg. 31 for possible problems and solutions.

Display Saver When the system is not used for more than 90 minutes, a decimal point will “scroll” across the X-axis display, indicating that the display saver has been activated. The display saver, like a screen saver on a computer monitor, will help prolong the life of your readout. If the display saver has been activated, press any key on the readout or move the table to return to the normal DRO view.

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SETUP Parameter Setup There are four parameters that you can define on your system: • • • •

Display resolution (diS) Linear error compensation (LEC) Scale resolutions (rES) Scale count directions (Ct dir)

Establish each setting the first time you power up the system. You can change the parameters later by returning to Setup and then using the ENTER key to scroll to the appropriate category. Anytime you change the linear error compensation, or count direction for an axis, the absolute and incremental displays for that axis will be reset to 0. If you change these settings, you will need to re-establish the datum point. For international units using 5µm (0.0002”) scales with reference marks, you will need to recall Datum. Refer to pg. 38 for instructions. When in the Setup mode, use the CLEAR key when you want to backspace, restore the previous value or access the previous parameter.

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SETUP Display Resolution The display resolution determines how detailed each scale’s position will be displayed on the readout. Use the setting that best suits each job. To change the display resolution: •

Press the SETUP key. (“diS” will show on the display.)

•

Press the X, Y, or Z key for the display you want to change. For 10µm scales, the display resolution will toggle between 0.01 mm (0.0005”) and 0.02 mm (0.001”). For 5µm scales, it will toggle between 0.005 mm (0.0002”) and 0.01 mm (0.0005”).

•

6

After you complete setting your display resolution, press ENTER to continue with setup or press ENTER then SETUP to return to the normal DRO display.

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SETUP Linear Error Compensation With MICRO-LINE, you can compensate for machine tool wear. If you know the linear error compensation (LEC) value in parts per million (PPM), you can enter it directly. If you don’t know the LEC, use the formula on the next page to determine the value for each axis. To change the linear error compensation: •

Move to the “Linear Error Compensation” display in the Setup mode. (Press SETUP and then the ENTER key until the display appears).

•

Press the X, Y, or Z key for the axis you want to change. MICRO-LINE will display the current LEC value for that axis.

•

Using the keypad, enter the linear error compensation factor (in PPM), followed by a + or - sign. The number must be within -9999 and 9999 (use whole numbers). The formula for calculating the value is on the next page.

•

After you complete setting your LEC, press ENTER to continue with setup or press ENTER then SETUP to return to the normal DRO display.

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SETUP How to Determine the Linear Error Compensation Follow this procedure for each axis: •

In the DRO mode.

•

Place a standard of known length on the table. Make sure it’s parallel with the table’s travel.

•

Put the readout in the absolute display mode (ABS/INCR key).

•

Using an edge finder or dial indicator, locate one end of the standard.

•

Press the ZERO key twice for the axis you are measuring. “0” should appear on the display.

•

Move the table along the axis until the edge finder or dial indicator reaches the opposite end of the standard.

•

Write down the length that is shown on the readout display for that axis.

•

Use the formula below to calculate the LEC for the axis you just measured. Enter the result in the LEC screen (previous page).

Note: If the measured length is greater than the standard length the LEC value will be negative. Formula S = Standard length M = Measured length

LEC =

(

S-M M

)

x 1,000,000

Example If the length of the standard you used is 10” and the measured length along the Xaxis is 9.995”, then the LEC for the Xaxis is 500 parts per million (PPM). 8

LEC =

LEC =

(

10 - 9.995 9.995

)

x 1,000,000

500 PPM (rounded to the nearest whole number)

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SETUP Scale Resolution To ensure accurate readings, the scale resolution shown for each axis must correspond with the resolution of the scales on your machine. To change the scale resolution: •

If necessary, choose “Scale Resolution” from the Setup menu. (Press SETUP and then the ENTER key until the screen appears).

•

Press the X-axis key until the appropriate resolution appears. Choose 0.01 mm for 10µm (0.0005”) scales and 0.005 mm for 5µm (0.0002”) scales (international units only).

•

Repeat the procedure for each axis.

•

Press ENTER to continue with Setup.

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SETUP Count Direction Use the count direction setting to define the positive counting direction for each scale. The direction will be displayed as a “1” or a “2” (the numbers are not assigned to a particular direction). You only need to change the count direction if the scale is counting in the negative direction during a positive table move, or vice versa. Refer to Conventions on pg. 37 for more guidelines. To change the count direction: •

Move to the “Count Direction” display in the Setup mode. (Press SETUP and then the ENTER key until “Ct dir” appears).

• Press the appropriate axis key (X, Y or Z). The current count direction (1 or 2) will appear. •

10

After you complete setting your count direction, press ENTER to continue with setup or press ENTER then SETUP to return to the normal DRO display.

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SETUP Testing the Scales Follow these steps to confirm that the scale has been installed properly. The Counting Test will confirm the scale’s electrical operation, and the Repeatability Test will check the installation integrity.

Counting Test •

Move the table along each axis, one at a time. Check that the readout correctly displays the table’s movement. If it doesn’t, then the scale resolution you selected may not be accurate. Refer to Scale Resolution on pg. 9 for instructions.

Repeatability Test •

Locate a magnetic base and dial indicator on the end of the scale. Zero the readout and the indicator.

•

Move the axis through the full travel and return the dial to “0.” The readout should also read 0 (±.0005” for 10µm scales; ±0.0002” for 5µm scales). If it doesn’t, then the scale cable may be loose, or the scale, mounting bracket, or reading head may need to be tightened or realigned.

•

Repeat these steps for each scale.

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O P E R AT I O N Setting the Datum (Absolute Zero) MICRO-LINE allows you to measure both absolute and incremental

dimensions. A dimension measured from the point you define as the datum is an absolute dimension. A dimension measured from any other point on your print is an incremental dimension. Datum, also known as absolute zero or workpiece zero, is the reference point from which MICRO-LINE will base all of your part’s coordinates. When the readout is in the ABS mode, it is actually measuring the distance from the datum to the table’s current position. You will need to establish a datum for every job. Your datum may already be identified on your print; if it isn’t, then establish a datum that allows you to enter most of your part’s dimensions directly, with the least number of calculations. All of the dimensions in the drawing below are based from the datum.

Datum

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OPERATION If you are using 5µm (0.0002”) scales (international units only), MICRO-LINE can recall your last datum position each time you

power up the system. Refer to pg. 38 for the proper procedure. To set the datum at the tool’s current position: •

Position the workpiece on the table. Move the table until the tool is centered on the edge of the workpiece at the location where you would like to establish the datum.

•

Using the ABS/INCR key, select the absolute (ABS) mode.

•

Press the X-axis ZERO key twice to establish the current X-axis position as the datum. Repeat for the Y- and Z-axes.

To set the datum using an offset: •

Using the ABS/INCR key, select the absolute (ABS) mode. Also check that the proper measurement (inch or mm) is selected.

•

Move the tool to a known point, i.e. the outside diameter of the workpiece or the face of the workpiece.

•

Press the ZERO key for the axis (X, Y or Z) you are entering a dimension for.

•

Using the keypad, enter the distance from your tool’s current location to the point you want to establish as the datum. Include a decimal point (.) and minus (-) sign when necessary.

•

Press the ZERO key for another axis, or press ENTER to return to the DRO display.

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OPERATION Example: Absolute Dimensions Let’s say that your print looks like this:

Datum

Here is how you would drill the holes using absolute dimensions. Notice that all of the dimensions are measured from the point that was established as datum (0, 0, 0). •

Check that “ABS” is selected on the DRO display (press the ABS/INCR key, if necessary). By selecting ABS, you’re telling MICRO-LINE to measure the machine’s movement on the X-, Y-, and Z-axes from your datum (0, 0, 0).

•

Press the MM key until “Inches” is selected (the MM display is not lit up).

•

For Hole 1, move the table until X = 2.00” and Y = 1.5”. Drill Hole 1.

•

Move the table until X = 4.00” and Y = 1.5”. Drill Hole 2.

•

Move the table until X = 6.00” and Y = 1.5”. Drill Hole 3.

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OPERATION Incremental Dimensions As described earlier, incremental dimensions are measured from the current tool position to the next. If the tool is currently at 2” and you want to move an additional 3.125”, you would select the incremental mode, zero out the axis, and move the table until the display reads 3.125. An example of how to measure using incremental dimensions is shown on the next page. To use an incremental dimension: •

Move the table to the point where you want to measure an incremental distance from.

•

Using the ABS/INCR key, select the incremental (INCR) mode on the readout. Also check that the proper measurement (inch or mm) is selected.

•

Press the ZERO key below the axis(es) from which you are measuring.

•

Move the table. MICRO-LINE will display the table’s position in relation to the “0” point(s) for the axis(es) you chose.

After you have reached the position you want and have milled the part, you can “zero” each axis again and then measure from that location to the next point on the workpiece or press ABS/INCR to return to the absolute mode.

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OPERATION Example: Incremental Dimensions Let’s say that your print looks like this:

Hole 1 is an absolute dimension (measured from the datum), while Holes 2 and 3 are measured incrementally. By putting MICRO-LINE in the incremental mode for the last two holes, you can measure their distances just as the print specifies, without any calculations. 1. Press the ABS/INCR key until “ABS” is selected on the DRO display. Press the MM key until “Inches” is selected (the MM display is not lit up). 2. For Hole 1, move the table until X = 2.00” and Y = 1.5”. Drill Hole 1. 3. Now press the ABS/INCR key so that “INCR” is selected on the DRO display. This tells MICRO-LINE that you want to measure the distance from the current position to the next point. 4. Press the ZERO keys that are below the X- and Y-axes keys. This resets the X- and Y-axes displays at “0.” 5. Move the table until X = 2.00” and Y = 0.000”. Drill Hole 2.

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OPERATION 6. Now repeat the process for the third hole. Press the ZERO key for the X-axis to measure from your tool’s current position. 7. Move the table until X = 2.00” and Y = 0.000”. Drill Hole 3.

Using Incremental Presets In the standard incremental mode, you would reset the display at “0” and move the table until the scale counts up to the point you want to reach. With the preset feature, you enter the distance you want to move first, and then count down to 0. For instance, if you enter 3.125” as the preset distance, MICRO-LINE will show -3.125 on the display. As you move the table in the positive count direction, the system will start counting. When the axis display reads “0,” your tool is in the correct position.

To preset an incremental position: 1. Press the key ( X, Y, or Z) for the axis you want to preset. MICRO-LINE will automatically switch to the incremental mode. 2. Enter the distance from your tool’s current position to the final location. Include a decimal point and minus (-) sign when necessary. 3. Repeat the step above for another axis or press ENTER to return to the DRO display. To reach the preset position, move the table until the display for each preset axis reads “0.”

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OPERATION Example: Incremental Presets

Datum Hole 1 is an absolute dimension because it’s measured from datum. Holes 2 and 3 are incremental dimensions (measured from one hole to the next) that you can preset. 1. Press the ABS/INCR key until “ABS” is selected on the DRO display. Also check that the system is in the “inches” mode (the MM key should not be lit up). 2. For Hole 1, move the table until X = 2.00” and Y = 1.5”. Drill Hole 1. 3. Now press the ABS/INCR key so that “INCR” is selected on the DRO display. This tells MICRO-LINE that you want to measure the distance from your current position to the next point. 4. Press the X key, enter 2 as the distance from Hole 1, and then press ENTER. Two inches is the incremental preset distance. 5. Move the table until X = 0.000” and Y = 0.000”. Drill Hole 2. 6. Press the X key (2.00 should already appear as the distance), and then press ENTER. Two inches is the incremental preset distance. 7. Move the table until X = 0.000” and Y = 0.000”. Drill Hole 3.

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OPERATION Centerline With MICRO-LINE, you can find the centerline (midpoint) between any two positions on your part. You can establish centerline as your datum by using absolute dimensions or you can create a centerline using incremental measurements without affecting your current datum. Refer to “Setting the Datum (Absolute Zero)” on pg. 12.

Setting the Datum on a Centerline 1. Press the ABS/INCR key until ABS is selected. 2. Move the table to the first location. 3. Press the ZERO key twice for the axis (X, Y, or Z) you want to find the centerline for. 4. Move the table to the second location along the same axis. 5. Press the C/L (centerline) key. Dashes will flash on the screen. 6. Press the appropriate key (X, Y, or Z) for the axis you’re measuring. 7. MICRO-LINE will measure the distance between the two points, then divide the sum in half. You can locate the centerline by moving the table until the position for the axis you measured reads “0.” Repeat the procedure to locate the midpoint for multiple axes. An example appears on the next page.

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OPERATION Example: Setting the Datum on a Centerline Here’s how you would establish the datum on the centerline of the part shown: 1. Using the ABS/INCR key, select the absolute (ABS) mode. Check that the proper measurement (inch or mm) is selected. 2. Rest the indicator against any point on the left or right side of the circle. (In graphic 1 above, we started on the left side.) Press the ZERO key for the X-axis twice. 3. Move the table until the indicator rests against the other side of the circle. Press the C/L (centerline) key. Press the X key, and MICRO-LINE will calculate the centerline between the two points. The display will show the distance from the current position to the centerline. 4. Now follow the same procedure for the Y-axis. Only this time rest the indicator against any point on the top or bottom half of the circle. Press the ZERO key twice for the Y-axis. 5. Move the table until the indicator rests against the other side of the circle. Press the C/L (centerline) key. Press the Y key, and MICROLINE will calculate the centerline and display the distance from the current position to the centerline.

Datum

20

Your datum is now located at the center of the circle.

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OPERATION Locating Centerline Using Incremental Dimensions 1. Press the ABS/INCR key to select the incremental display mode. 2. Move the table to the first location. 3. Press the ZERO key for the appropriate axis. Doing so will zero the current position. 4. Move the table to the second location along the same axis. 5. Press the C/L (centerline) key. Dashes will flash on the screen. 6. Press the appropriate key (X, Y, or Z) for the axis you’re measuring. 7. MICRO-LINE will measure the distance between the two points, then divide the sum in half. You can locate the centerline by moving the table until the position for the axis you measured reads “0.” 8. Repeat the procedure for each axis.

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OPERATION Bolthole Patterns Creating a Bolthole Pattern

Hole 1

A bolthole pattern is defined by its number of holes (up to 99), center point, radius, and start angle. MICRO-LINE will automatically position “Hole 1” at the start angle and space the holes equally throughout the pattern.

To create a bolthole pattern: 1. Press the BOLT DEF key. "HOLES" will appear on the X-axis display. 2. Enter the number of holes (1-99) in the pattern. Press the ENTER key. 3. Press the ENTER key again. “Center” will appear, and then a flashing dash will appear on the X- and Y-axes. 4. Press the X key. Using the keypad, define the center point of the bolthole pattern on the X-axis. Use a decimal point and minus (-) sign when necessary. 5. Press ENTER.

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OPERATION 6. Press the Y key. Enter the bolthole pattern’s center point on the Y-axis. Use a decimal point and minus (-) sign if necessary. 7. Press the ENTER key. 8. Press the ENTER key again. “Radius” will appear. 9. Enter the radius of the circle pattern. Press ENTER. 10. Press ENTER again. "START" will appear on the X-axis display. 11. Enter the start angle of the first hole in the bolthole pattern. (0 degrees is at the 3 o’clock position.) Use a decimal point and minus (-) sign if necessary. 12. Press ENTER to complete the pattern.

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OPERATION Running a Bolthole Pattern When you run a bolthole pattern, MICRO-LINE always assumes that you want to start with the first hole. It will display “Hole 1,” and then the distance to the hole from your tool’s current position. Move the table until it reaches 0, 0. After you’ve drilled the hole, press the BOLT USE key again, and “Hole 2” will appear. Move the table to “0,” drill the hole and continue with the rest of the pattern. If you want to start at a different place in the pattern, press BOLT USE followed by the number of the hole you want to begin with. Notice that the system automatically switches to the incremental mode whenever you run a pattern. That’s because the system is using incremental presets (pg. 17) to measure from one hole to another. As with any preset, you can find the current hole’s location by moving the table until the displays for both the X- and Y-axes read “0.” After you’ve completed the operation, you may either keep the readout in the incremental mode or press the ABS/INCR key to switch to absolute measurements. To run a bolthole pattern:

•

Press the BOLT USE key. "HOLE" will appear on the X-axis display. The number of the first hole to be milled will appear on the Y-axis display. (To select a different hole, refer to the note on the next page.)

•

MICRO-LINE will display the distance to the hole you’ve chosen.

Move the table until the X- and Y-axes both read “0.” Drill the first hole. •

24

Press the BOLT USE key again. Move the table until the X- and Y-axes read “0.” Drill the second hole. Repeat the procedure for each hole in the pattern.

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OPERATION Note:

To select a different hole in the pattern, press the BOLT USE key and immediately press the number of the hole you want to mill. Press “2” on the keypad for Hole 2, “3” for Hole 3, etc. The holes are numbered counter-clockwise from the start angle. You can also scroll through the series of holes by pressing the BOLT USE key repeatedly.

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TROUBLESHOOTING Troubleshooting Introduction Refer to this troubleshooting guide whenever you have questions or concerns about the operation of the MICRO-LINE system. This guide is arranged in three columns entitled Symptom, Probable Cause and Recommended Corrective Action. The symptoms are listed in the order of the most common, easiest to check, and least expensive to correct. First locate the symptom that best describes the problem you are trying to solve. Then identify the probable cause that most closely matches the problem and implement the recommended corrective action. If a problem persists or cannot be resolved using this manual, contact your MICRO-LINE distributor for further assistance.

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TROUBLESHOOTING Symptom

Probable Cause

Screen is blank

No power to the readout

Recommended Corrective Action Check that the power switch on the back of the console is “on.” Check that the readout’s power cord is properly connected to the power supply. Check the fuse. (Located above the power switch). Check that the power source meets the specifications required by your system (pg. 33).

LED failure

Contact your MICRO-LINE distributor for repair/ replacement procedures.

Decimal point scrolls across display

System has been idle for approximately 90 minutes and is in “display saver” mode

Press any key or move the table to return to the previous screen.

Dashes appear on screen

Display overflow

The value entered exceeds the display’s 8-character capability. Enter a value with less than 8 characters. (cont’d next page)

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TROUBLESHOOTING Recommended Corrective Action

Symptom

Probable Cause

Dashes appear on screen (cont’d)

Display overflow

Move the table toward the “0” position. As the scale counts down, the display will show the correct position.

Error message (E1) appears

Power loss occurred

This is a normal message at power up. If the message appears at any other time during operation, a problem may have occurred. Refer to pg. 31 for details.

Error messages (E2E58) appear

Causes vary

Turn the system “off” and then “on” again, using the switch on the back of the readout. If an error (besides E1) is still detected when the system is powered up, contact your MICROLINE distributor for repair/replacement procedures. Refer to pgs. 31 - 32 for a list of error messages.

Keys not working properly

Invalid keypress

Turn the system “off” and then “on” again, using the switch on the back of the readout. If an error (besides E1) is still detected when the system is powered up, contact your MICRO-LINE distributor for repair/replacement procedures. Refer to pg. 3132 for a list of error messages.

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TROUBLESHOOTING Recommended Corrective Action

Symptom

Probable Cause

Scale won’t count

Loose cable

Check that the scale cable is securely connected to the readout.

Wrong input

Check that the scale cable is connected to the correct input on the back of the readout. Refer to the readout installation instructions.

Scale not installed properly

Check the scale and reading head for proper installation (refer to scale installation instructions).

The scale’s reading head is not working properly

Unplug the scale from the readout and plug it into an input for another axis. If the scale still does not count, the reading head may need to be replaced. If the scale counts on the other axis then the display may need to be replaced. See LED Failure.

Wrong scale resolution

Check that the correct scale resolution for the correct axis was selected (pg. 9).

Wrong count direction

Change the count direction (pg. 10).

Scale not installed properly

Check the scale and reading head for proper installation (refer to scale installation instructions included with your system). Clean the scale, if necessary.

Scale counts, but not correctly

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TROUBLESHOOTING Recommended Corrective Action

Symptom

Probable Cause

Setup does not save values

Improper procedure

Press the ENTER key after each value is entered into a Setup screen. If you press another key instead, the new value will not be saved. Refer to pgs. 5 - 10 for proper procedures.

Numbers don’t appear/are faded on the display

LED failure

Turn the system “off” and then “on” again, using the switch on the back of the readout. If this does not correct the problem, contact your MICRO-LINE distributor for repair/replacement procedures.

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TROUBLESHOOTING Error Messages (General) When MICRO-LINE is powered up, it will run a series of tests to ensure that the software is working properly. If an error message appears, refer to the charts on this page and the next for a diagnosis and solution.

E1

A power loss has occurred. This message will appear every time you power up the system and can be cleared by pressing the CLEAR key. If the E1 message appears at any time other than at power up, a power interruption has occurred and your current table position may be lost. Re-establish the datum if necessary. If the problem persists, contact your distributor for repair/replacement procedures.

E2

An EEPROM memory error has occurred. Press the CLEAR key to acknowledge the error. The datum and setup information may be lost. These areas should be checked and reestablished upon power up. If the problem persists, contact your distributor for repair/replacement procedures.

E3

A ROM memory error has occurred. Press the CLEAR key to acknowledge the error. If the system does not operate properly, contact your MICRO-LINE distributor for repair/replacement procedures.

E4

A random access memory (RAM) error has occurred. Press the CLEAR key to acknowledge the error and continue with the next test. If the system does not operate properly, contact your MICRO-LINE distributor for repair/replacement procedures.

E9

A scale miscount error (invalid waveform) error has occurred. The E9 message will appear on the axis that has the error. Press CLEAR to reset the axis(es). Your current position may be lost. Re-establish the datum if necessary. If the system does not operate properly, contact your MICRO-LINE distributor for repair/replacement procedures.

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TROUBLESHOOTING Error Messages (Keypad Test) The messages below indicate that a problem was found during the keypad test at startup. If an error message appears, turn the system off, press the appropriate key to release it back into position, and then restart the system. (Or you can press the CLEAR key to clear the error message.) If the key does not work during normal operation, contact your distributor for repair/replacement procedures.

E11

SETUP key

E35

5 key

E12

C/L key

E36

4 key

E15

MM key

E38

Y key

E16

ABS/INCR key

E41

3 key

E18

X key

E45

2 key

E21

9 key

E46

1 key

E22

BOLT DEF key

E48

ZERO key for the

Y-axis

E25

8 key

E51

± key

E26

7 key

E54

ENTER key

E28

ZERO key for

E55

0 key

the X-axis

E31

6 key

E56

Decimal point (.)

E32

BOLT USE key

E57

ZERO key for the

key

Z-axis

E33 32

CLEAR key

E58

Z key

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REFERENCE Electrical Specifications Follow these specifications when installing your MICRO-LINE system.

Characteristic

Specification

Operating conditions

0° to 40°C (32° to 104°F) 25% to 85% relative humidity (non-condensing)

Storage conditions

-40° to 60°C (-40° to 140°F) 25% to 85% relative humidity (non-condensing)

Input requirements: Voltage Frequency Current

115VAC or 230VAC, single phase 47 - 63Hz per channel 300mA @ 115V, 150mA @ 230V

Fuse

115V operation: 1/2A, 250V, 3AG, slo-blo 230V operation: 1/4A, 250V, 3AG, slo-blo

Encoder input

Position signals: channels A & B TTL square wave signal in quadrature (90° nominal phase relationship) Maximum input rate: 70 kHz

Size

9.875” x 4.679” x 4.75”

Weight

4 lbs., 2 oz.

Mounting

Bottom; two 1/4”-20 threaded inserts

FCC compliance CE compliance

Part 15 of FCC rules for a class A computing device For Europe

ETL compliance

For United States

ETLc compliance

For Canada

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REFERENCE Factory Default Settings Display Resolution

High (0.0005"/0.01 mm for 10µm scale)

Linear Error Compensation

0 parts per million

Scale Resolution

0.0005”/0.01 mm (10µm)

Count Direction

1

Bolt Circle

34

Number of Holes

1

Center

(0, 0)

Radius

0

Start Angle

0 degrees

Display Units

Inches

Display Mode

ABS (absolute dimensions)

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REFERENCE Keypad Here’s an overview of the MICROLINE keypad. Each key’s function is described below.

X, Y, Z

Correspond with the scales on the X-, Y-, and Z-axes. Used to specify a change to a particular axis.

ZERO

Three keys reset the incremental or absolute display position at “0” for the corresponding axis.

ABS/INCR

Used to switch between absolute (ABS) and incremental (INCR) measurements. The active mode will be displayed at the top of the DRO display.

MM

Press this key to switch X, Y & Z displays between English and metric units.

SETUP

Provides access to the display resolution, linear error compensation, scale resolution, and scale count direction operations.

C/L (CENTERLINE)

Locates the centerline of the workpiece (pg. 19).

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REFERENCE

36

BOLT DEF

Used to create a bolthole pattern.

BOLT USE

Used to run a bolthole pattern.

CLEAR

Acts as backspace key during numeric entry; otherwise, it clears or cancels the last operation.

ENTER

Completes numeric operations; selects next parameter in SETUP or BOLT DEF operations.

±

Changes the sign of the entered value from positive(+) to negative(-) or vise versa. Numbers are positive unless a (-) appears in front of them.

.

Decimal point can be used during numeric entry; also used to access the recall feature for systems with 5µm (0.0002”) scales after power up.

0-9

Used to enter a distance, angle, or other number value.

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REFERENCE Conventions This section identifies the standard conventions that apply to your MICRO-LINE system.

DRO Mode The MICRO-LINE system is considered to be in the DRO (digital readout) mode when the X- and Y-axes positions are displayed for a 2-axes system, and the X-, Y-, and Z-axes positions are displayed on a 3-axes system.

Count Direction MICRO-LINE uses positive and negative numbers to determine the posi-

tion of the table and tool on each axis. The graphic below shows a typical setup for the positive and negative count directions for the X-, Y-, and Z-axes on a vertical knee mill. All of the examples in this manual are based upon this setup. X-axis: The table will move to the left and the tool will move to the right for a positive count direction. Y-axis: The table will move toward you while the tool moves away from you for a positive count direction. Z-axis: The quill will move up (away from the table surface) for a positive count direction.

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REFERENCE Recalling the Last Datum Setting For International Units If you are using 5µm MICRO-LINE scales, MICRO-LINE can retrieve your last datum setting when you power up your system. This feature is especially useful when you have to shut down the system in the middle of a job, or if a power interruption occurs. When power is restored, MICRO-LINE will use Position-TracTM technology to read the scales’ reference marks and recall the datum within seconds. The recall feature only works after you have completed the initial system setup and established a datum, so it won’t be accessible the very first time you turn the readout on. After you have completed those operations, you can recall the datum for every power up thereafter.

To recall your last datum: •

Power up the system.

•

Press the CLEAR key to clear the E1 message.

•

Press the decimal point (.) on the readout’s keypad. Move the table in the positive count direction along the X-axis. Keep moving it until the system recalls the datum and “found” flashes on the screen. The system will automatically reset the X-axis value to reflect the distance from the table’s current position to the datum. Repeat this step for the Y- and Z-axes, always moving the machine in the positive count direction.

After you have completed the recall procedure, you can move to the datum by positioning the table, saddle, and quill until the display reads “0” for each axis.

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REFERENCE Notes:

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SCALE INSTALLATION General Installation Instructions for the Scale Specific instructions may be included that will supersede this section. Please do not expose the scale to the following:

Installation Brackets

• •

40

Installation brackets and tools are already included with each system. Your Authorized ACU-RITE Distributor can assist you in selecting brackets and tools for your installation. MICRO-LINE

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SCALE INSTALLATION Introduction The MICRO-LINE precision glass scale provides the accuracy and reliability of an ACU-RITE measuring system. Features and options include: • • • • •

• •

Digital resolutions of 5 or 10µm. Accuracy Grade of ± 10µm/1000mm. Home reference signals on international units only. Braided cables in 10ft., 15ft., or 20ft. lengths. Two scale case forms: • Top mounting scale available 2 - 120” measuring length • End mounting scale available 2 - 22” measuring length Mounting Fasteners Installation Brackets

See Page 2 to fill out warranty record information. Scale mounting hardware and cable mounting hardware are provided with each MICRO-LINE scale.

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SCALE INSTALLATION Mounting Preparation • • • • •

Understand your mounting requirements. Mount with lipseals down and away from the work area. Brackets should be kept as short and rigid as possible. Clean all mounting surfaces. Ensure the correct length scale is being used for the total machine travel. Do not remove alignment brackets until instructed.

Never mount with lipseals upward or toward work area.

Equipment travel must not exceed scale measuring length.

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SCALE INSTALLATION Mounting Information • •

Mount the scale close to machine guide ways to ensure system accuracy. Follow kit instructions when using an ACU-RITE bracket kit.

Gap .005 - .180 max.

• •

•

A gap greater than .18” between the reading head and mounting surface requires a spacer or bracket. Reading head leveling set screws are provided to adjust the gap between the reading head and mounting surface.

Tolerances of .010” TIR apply to all mounting dimensions.

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SCALE INSTALLATION Scale Dimensions End Mounted Scale Form

Top Mounted Scale Form

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SCALE INSTALLATION Mounting Illustrations End Mounted Scale Form

Top Mounted Scale Form

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SCALE INSTALLATION Installation Procedure These steps apply to typical mounting conditions. Although this may not pictorially represent your application, your installation procedure should follow these steps. ACU-RITE bracket kit instructions supersede this section. • •

Adjust drill depths and fastener lengths as required. Contact your Authorized ACU-RITE Distributor if assistance is required.

First Steps: 1. Move the axis to its center of travel. 2. Mark the axis location so that it can be re-centered easily. 3. Slide the reading head with the alignment brackets attached, along the scale case to the center of the scale case.

4. Locate the bottom of the end cap flush with the axis parting line. 5. Mark one end mounting hole. 6. Drill and tap the hole location 10-32 x 1/2” deep for the top mounting form and a 1/4-20 x 1/2” deep for the end mounting form. Attach the scale.

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SCALE INSTALLATION

7. Align to within .010” TIR to axis of travel and mark the second end mounting hole. Remove scale, drill and tap correct hole size. 8. Attach the scale and align to within .010” TIR to axis of travel. 9. Top mounting requires the top surface to be indicated to within .010” TIR over each mounting hole. Mark remaining hole locations. Remove scale, drill and tap remaining holes. Attach the scale and align to within .010” TIR to axis of travel. 10. For end mounting form, after scale is attached and aligned, insert mounting hole covers. 11. Ensure the axis is still at its center of travel and the reading head is centered on the scale. Mark the reading head mounting holes. 12. Move the axis and drill and tap for 8-32 (M4).

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SCALE INSTALLATION

13. Move the axis to align reading head mounting holes. 14. A gap must exist between the reading head and the mounting surface. 15. Adjust the leveling screws, using a .001" -.003" feeler gage (or shim) between the leveling screw and the mounting surface. Adjust the leveling screw until a slight drag is felt on the feeler gage. Repeat this for each leveling screw, 3 total. 16. Evenly tighten the two 8-32 SHCS to secure the reading head.

17. Use the Allen wrench from the leveling screw adjustment to slide brackets away from the reading head. 18. Remove the alignment brackets and save with this Reference manual. 19. Route cable with slack loops allowing for axis motion. 20. Secure excess cable by fastening with clips and ties. 21. Move the axis through its full travel. Confirm that the assembly does not interfere with the machine movement. 48

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WARRANTY Hassle-Free Warranty ACU-RITE readouts and precision glass scales are warranted to the end user against defects in material and workmanship and against any damage that occurs to the product within three (3) years from the original purchase date. ACU-RITE will, at its discretion and expense, repair or replace the returned item or any of the item's component(s) as long as ACU-RITE receives notice of the defect or damage within the three (3) year warranty period. The foregoing warranty obligations are in lieu of all expressed and/or implied warranties of fitness or merchantability or otherwise, and state ACU-RITE's entire liability and the end user's exclusive remedy, under any circumstance, for any claim of damage. In no event shall ACU-RITE be liable for incidental or consequential damages nor shall ACU-RITE's liability for any claims or damage arising out of or connected with this warranty or the manufacture, sale, delivery, or use of the products with which this warranty is concerned exceed the purchase price of said products.

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MICRO-LINE

™

For Milling Applications

REFERENCE MANUAL

lllllllllllllllll ACU-RITE INCORPORATED One Precision Way • Jamestown,NY 14701

Readout Systems Precision Glass Scales